Insulated component wall finishing system

ABSTRACT

An insulated wall finishing system consisting of several components all of which have a central core made of rigid foam core material such as EPS foam. One or both sides of the central core are laminated with a gypsum product, formica, wood or wood by-products. The components consist of a straight wall panel, a corner column and Partition “T”, when combined and interconnected allows the installer to construct a perimeter wall and interior walls. Each wall panel further contains a plurality of right-angled metal supports oriented vertically within the panel, which allow for more rigidity and also offer a point of attachment for heavy objects such as pictures, cabinets, televisions and similar object. Each wall panel further contains a plurality of vertical holes or chases oriented vertically within the panel to allow for the routing of plumbing, electrical and audio visual utilities within the panel. A method to use the wall panel system, Corner Columns and Partition “T” to assemble and construct perimeter and interior walls.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to insulating wall panels and member components. More particularity, to a system of panels that are mountable to existing masonry walls, as in basement finishing applications, new construction and renovation projects, for existing buildings.

SUMMARY OF THE INVENTION

The insulated wall finishing system is a system for finishing masonry walls, new construction and existing building structures. The finishing system comprises a plurality of connectable panels and components. The panels are made from a rigid insulation core. The core is laminated on opposite sides with a rigid material that will define the interior finished surfaces of the walls.

The insulation core acts as a waterproof insulating vapor barrier in the application of basement wall finishing and adds structural support to the panels. The insulation core is a flat smooth surface that accepts an environmentally approved adhesive which bonds to the interior finished surface.

The insulation core contains a plurality of vertically oriented, wire/plumbing chases. These said chases provide easy access for wiring/plumbing during and after the installation of the panels.

The panels are given additional tensile strength with inserted vertical metal supports, placed between the insulation core and the finished interior surfaces. In the preferred embodiment there are a total of six vertical metal supports installed in each, three on opposite sides of the insulation core. In addition to providing tensile strength, these supports eliminate future bowing or flexing in the panel and offer mounting support for wall cabinets, wall hangings, televisions and other heavy objects. Additionally, the finished panel is a prefabricated studded wall which eliminates the need for conventional framing.

The insulation core has two vertical grooves, one on each end of the panel, creating an assembly joint. This joint accepts a component spline that, when inserted into the groove provides a tight and flush panel joint for seam finishing. This spline is also made of the same or denser insulating material as the core, thus maintaining the insulation properties at the panel joint.

The panel is part of a component system which includes two other components: a Corner Column and a Partition “T”. The Corner Column has the same insulation core material as the panel and is formed into a 90 degree finished wall section. The Corner Column is given additional tensile strength with inserted vertical metal supports. In the preferred embodiment there are a total of two, vertical metal supports installed, one on the inside of the 90 degree corner, one on the outside of the 90 degree corner between the insulation core and the finished interior surfaces. The insulation core is laminated on all sides with the interior finished surface. The Corner Column is used for all inside and outside corner applications and eliminates the need for cutting and building in the field. As with the panel construction, the Corner Column has two vertical grooves, one on each end, to create an assembly joint. This joint accepts a component spline that, when inserted into the groove provides a tight and flush panel joint for seam finishing.

The Partition “T” has the same insulation core material as the panel and is formed into a T-shaped wall section. The Partition “T” is given additional tensile strength with inserted vertical metal supports. In the preferred embodiment there are a total of three, vertical metal supports installed, one at each 90 degree corner and one centered on the panel side between the insulation core and the finished interior surfaces. The insulation core is laminated on all sides with the interior finished surface. The Partition “T” is used to intersect any wall panel where an adjacent partition wall is required and eliminates the need for cutting and building in the field. Similar to the panel construction, the Partition “T” has three vertical grooves, one on each end, to create an assembly joint. This joint accepts a component spline that, when inserted into the groove provides a tight and flush panel joint for seam finishing.

Metal mounting brackets, readily available from local building suppliers, are used in the assembly and mounting of all components in the application of an existing masonry wall. The system provides top mounting brackets and bottom mounting brackets. The top mounting bracket, known as a Hat Track, is secured at the top of the masonry wall, just below the ceiling, and extends the entire length and perimeter of the walls. The bottom mounting bracket is L-shaped and is secured along the floor and extends the entire length and perimeter of the existing wall. Each panel and component is secured inside the bottom bracket and fastened to the top bracket with metal screws.

The wall finishing system of the present invention significantly reduces the need for framing studs and labor intensive conventional construction. Furthermore, the present invention can be used in any building application, residential or commercial, new construction or existing building renovations. Additionally, the insulation core of the invention provides thermal control and acoustic properties desired in commercial structures, such as office complexes and healthcare buildings, where privacy rooms and zoned HVAC control is needed.

These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.

DESCRIPTION OF PRIOR ART

There are several different types of insulated wall panels existing. However, the majority of these panels do not provide for ease of connectivity, the component system for interconnecting the panels, the structural support or the wire chases. The prior art can be separated in various sub-categories that disclose similar components to the present invention.

U.S. Pat. No. 5,349,796 to Meyerson, U.S. Pat. No. 5,086,599 to Meyerson, U.S. Pat. No. 4,833,855 to Winter, U.S. Pat. No. 3,357,146 to Gartrell, U.S. Pat. No. 5,348,778 to Knipp, and U.S. Pat. No. 3,410,044 to Moog all disclose a wall panel consisting of rigid thin laminate layers surrounding a foam or similar low density material. These wall panel systems also disclose a tongue and groove or modified tongue and groove method of connection in order to create a solid wall appearance. The present invention does comprise one or two thin laminate layers secured to a low density foam material. However, the present invention differs in that, it uses a groove and spline method of attachment. This allows the panels to be flipped and used interchangeably and not be restricted to mounting the panels in one orientation. Each panel has a grooved end on both lateral ends of the panel, through the use of the spline an installer is not restricted to orienting the panel in one direction. By not requiring the installer to orient the panels, based on the tongue and groove lay-out, the panels to be constructed less expensively because only one side of the panel must be made with a finished surface.

Further, the present invention differs from these panel systems in that it contains structural supports for rigidity and for the mounting of cabinets, pictures, televisions and other heavy objects. Finally, the present invention differs from these panel systems in that it also contains vertical pre-drilled chase holes, for the purpose of routing utilities such as pipes, electrical wires and audio/visual cabling.

U.S. Pat. No. 5,519,971 to Ramirez, U.S. Pat. No. 4,694,624 to Juhas and U.S. Pat. No. 3,449,879 to Bloom disclose vertical pre-drilled holes through the similar panels to the present invention. However, in U.S. Pat. No. 4,694,624 to Juhas and U.S. Pat. No. 3,449,879 to Bloom the purpose of the holes are as a method of reinforcing the panel and adding additional rigidity to the panel. U.S. Pat. No. 5,519,971 to Ramirez discloses a vertical hole for the routing of electric and water service. Additionally, the inventors are aware of two apparatuses known as the TEMO wall panel and the Basement Tuxedo panel both of which have a wire chase predrilled into the panel. The present invention differs from these disclosed inventions in that it contains structural supports for additional rigidity and for attachment of heavy pictures, cabinets and televisions. Further, the present invention consists of a component system, consisting of Column Corners and Partition “T”'s which allow for more rapid installation, by reducing cutting and molding and for a more custom appearance upon completion by reducing the number of visible seams.

U.S. Pat. No. 5,842,276 to Asher and U.S. Patent Application 2007/0227086 from Beavers all disclose a wall panel system with structural supports oriented vertically within the wall panel system. Both disclose a vertical metal support to add strength and rigidity to the wall panel. In U.S. Patent Application 2007/0227086 from Beavers the metal supports are primarily used for a method of securing a plurality of foam blocks forming the wall panel system. U.S. Pat. No. 5,842,276 to Asher discloses vertical metal supports, however, these are more similar to a traditional metal stud than the metal supports in the present invention. These wider and larger metal studs do not allow for a thermal break as they span the entire width of the panel. In the present invention the metal supports do not span the entire width of the panel which prevents the transmission of thermal energy from one surface of the panel to the other which results in a loss of the panel's insulating qualities. Further, U.S. Pat. No. 5,842,276 to Asher and U.S. Patent Application 2007/0227086 from Beavers disclose only wall panels which are connected with a butt joint. The present invention consists of a component system, consisting of Column Corners and Partition “T”'s which allow for more rapid installation, by reducing cutting and molding and for a more custom appearance upon completion by reducing the number of visible seams.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the insulated Wall Panel which is the main component of the system, according to the present invention.

FIG. 2 is a perspective view of the Corner Column and is a component member to the Wall Panel in FIG. 1, according to the present invention.

FIG. 3 is a perspective view of the Partition “T” and is a component member to the Wall Panel in FIG. 1, according to the present invention.

FIG. 4 is a perspective view of the Spline member of the system, according to the present invention.

FIG. 5 is a perspective view of the assembly method of all component members, according to the present invention.

FIG. 6 is a perspective view of the completed assembly of the wall system, according to the present invention.

FIG. 7 is a perspective view of the L bracket

FIG. 8 is a perspective view of the Hat Track.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF INVENTION

Referring in detail to the drawings, member components of the invention are identified by like reference numerals. The Wall Panel member, generally illustrated as 11, is produced in accordance with the present invention. The Wall Panel member 11 comprises an Expanded Polystyrene (EPS) foam core or similar rigid insulating foam material which has adequate insulation qualities to provide a rating of R4 per inch, generally illustrated as 1, with a pair of vertically opposed ends 17 and 18 (see FIGS. 1, 2 & 3). End 17 being the top or upper end of the Wall Panel and End 18 being the bottom or lower end of the Wall Panel. The EPS foam core 1 may be either high density and/or low density. A density from one pound per cubic foot to three pounds per cubic foot is used in the preferred embodiment and has been found to provide excellent thermal properties as well as excellent physical properties including strength.

There is a plurality of vertical circular openings 2 passing vertically through the EPS foam core of the Wall Panel 1 from the Upper End 17 to the Lower End 18. These circular openings 2, known as wire/plumbing chases, may be employed for any suitable use such as routing electrical wiring, water and gas lines, etc. (see FIGS. 1, 5, & 6).

There is a plurality of vertical metal right-angle supports 3 that pass into a slot 4 which has an inner side 21 and an outer side 22 (see FIGS. 1, 5, & 6) and run vertically through the EPS foam core of the Wall Panel 1 from the Upper End 17 to the Lower End 18. The sides of the slot 21 and 22 are oriented at a right angle to each other. The plurality of slots 4 are cut into the foam core 1 prior to the interior finish surfaces 10 being affixed to the foam core. Each metal support member 3 includes an inner side 19 and an outer side 20 which are oriented at a right angle to each other. The metal support member 3 is inserted into slot 4, in a manner such that inner side 19 aligns with inner slot 21 and outer side 20 aligns with outer slot 22 and is surrounded by the EPS foam core 1. Metal support member outer side 20 lies flush against the EPS foam core 1 in slot 22. These metal support members 3 are mirrored on both sides of the panel member 11, such that the inner sides of any opposing metal support members are not in the same plane which is perpendicular to the panel member 11. With the metal support arranged in this manner additional tensile strength is added, which eliminates any bowing or flexing and acts as an internal mounting bracket for mounting cabinets, flat screen TVs and other wall hangings.

The EPS foam core of the Wall Panel 1 includes opposing lateral ends 5 and 7 (each a defined edge). End 5 is formed with a channel groove 6 and end 7 is formed with a similar channel groove 8 (see FIGS. 1, 2, 3 & 5).

The EPS foam core 1 provides significant insulating qualities and thereby reduces heating and cooling costs as compared with conventional fiberglass batt insulation of equal thickness. Furthermore, the EPS foam core 1 in combination with the plurality of metal support members 3 and laminated interior finish surfaces 10 may be custom specified to provide complete design flexibility and superior structural advantages in strength and lateral load capabilities.

The interior finish surfaces 10 may be of a variety of substrates such as any Gypsum product, Formica, Wood and Wood by-products, etc. The bonding adhesive 9 is applied on both sides of the EPS foam core 1 and then the interior finish surfaces 10 are laminated to the adhesive for a permanent bond. The bonded interior finish surfaces encapsulate the EPS foam core 1 and metal supports 3, completing the Wall Panel 11 (see FIGS. 1, 5 & 6).

The completed Wall Panel 11 of the present invention provides for prefabrication that eliminates the need for conventional construction methods and may be easily installed at a building site in housing construction or renovation, industrial building, or any other structure requiring finished walls.

The Corner Column, generally illustrated as 12 (see FIG. 2) is comprised of the EPS foam core 1, which is formed into a solid ninety (90) degree angle column. The EPS foam core 1 includes lateral ends 26 and 28 (each a defined edge). End 26 is formed with a channel groove 27 and end 28 is formed with a channel groove 29 (see FIGS. 2 & 5). These lateral ends 26 and 28 are equal in all dimensions to the lateral ends 5 and 7 on the Wall Panel 11. The channel groves 27 and 29, are equal in all dimensions to the channel groves 6 and 8 on the Wall Panel 11. There is a plurality of vertical metal right angle supports 3 (see FIGS. 2, 5, & 6) which run vertically through the EPS foam core 1 from the upper end 17 to the lower end 18. The metal support member 3 is oriented in such a manner that one side 19 is parallel to the finished surface 10 and the opposing side 20 is parallel to the opposing finished surface 10 In the preferred embodiment one metal support member 3 is located at the apex of the interior right angle of the Corner Column and a second metal support member 3 is located at the apex of the exterior right angle of the Corner Column 12, to provide the necessary strength and stability for each Corner Column 12.

The interior finished surfaces 10 may be of a variety of substrates such as any gypsum product, formica, wood and wood by-products, etc. The bonding adhesive 9 is applied on both sides of the EPS foam core 1 and then the interior finished surfaces 10 are laminated to the adhesive for a permanent bond. The bonded interior finished surfaces encapsulate the EPS foam core 1, completing the Corner Column 12 (see FIGS. 2, 5 & 6).

The completed Corner Column 12 of the present invention provides for prefabrication that eliminates the need for conventional construction methods and may be easily installed at a building site in housing construction or renovation, industrial building, or any other structure requiring finished walls.

The Partition “T”, generally illustrated as 15 (see FIG. 3) is comprised of the EPS foam core 1, which is formed into a solid T-shaped wall section. The EPS foam core 1 includes ends 13, 30 and 32 (each a defined edge). End 13 is formed with a channel groove 14, end 30 is formed with a channel groove 31 and end 32 is formed with a channel groove 33 (see FIGS. 3 & 5). These lateral ends 13, 30 and 32 are equal in all dimensions to the lateral ends 5 and 7 on the Wall Panel 11 and the lateral ends 26 and 28 on the Corner Column 12. The channel groves 14, 31, and 32 are equal in all dimensions to the channel groves 6 and 8 on the Wall Panel 11 and channel groves 27 and 29 on the Corner Column 12.

There is a plurality of vertical metal right-angle supports 3 (see FIG. 3) and run vertically through the EPS foam core 1 from the upper edge 17 to the lower edge 18.

In the preferred embodiment three metal support members 3 are used, one is located at the interior of one of the right angles of the Partition “T” 15, the second is located at the interior of the other of the right angles of the Partition “T” 15, and the third is located near the center of the top of the T portion of the Partition “T” 15. The third metal support member 3 is inserted into a slot 4 in a manner similar to that used for the wall panel component 11, in that a slot 4 is cut into the panel prior to the attachment of the interior finished surface 10.

The interior finished surfaces 10 may be of a variety of substrates such as any gypsum product, formica, wood and wood by-products, etc. The bonding adhesive 9 is applied on all sides of the EPS foam core 1 and then the interior finished surfaces 10 are laminated to the adhesive for a permanent bond. The bonded interior finished surfaces encapsulate the EPS foam core 1, completing the Partition “T” 15 (see FIGS. 3, 5 & 6).

The completed Partition “T” of the present invention provides for prefabrication that eliminates the need for conventional construction methods and may be easily installed at a building site in housing construction or renovation, industrial building, or any other structure requiring finished walls.

The Spline member, generally illustrated as 16 (see FIG. 4) is made of the EPS foam core 1 and has ends 23, 24, and sides 25 and 26. The spline member 16 provides the jointing and method of assembly of all system components. The density of the EPS foam core 1 for the Spline member 16 should be equal to or denser than any other system Wall Panel 11, Corner Column 12 or Partition “T” 15. In the preferred embodiment the Spline is one pound denser than the Wall Panel 11, Corner Column 12 or Partition “T” 15. This increased density provides additional strength and a tighter and better aligned joint between system members. Additionally, sides 25 and 26 are made thicker in the center and taper to the ends 23 and 24. The tapered ends 23 and 24 make it easy to insert in the groove channels 6, 8, 14, 27, 29, 31 and 32 of the respective system components, as the thicker center tightens the joint, making the interior finished surfaces 10 flush (see FIG. 5).

For use of the Corner Columns, the Spline member 16, and more specifically ends 23 and 24 are inserted into the groove channels 6 and 8 of consecutive Wall Panels 11 until the wall has reached an inside or outside corner of the room (see FIGS. 5 & 6). For inside and outside corner applications the Corner Column 12 is joined to the Wall Panel 11 by inserting the Spline member 16 and more specifically ends 23 and 24 into the groove channels 6, 8, 27, and 29 of the Wall Panel 11 and Corner Column 12.

For use of the Partition “T”, the Spline member 16, are inserted into the groove channels 6 and 8 of consecutive Wall Panels 11 until the wall has reached an intersection of a wall (see FIGS. 5 & 6). For intersecting walls the Partition “T” 15 is joined to the Wall Panel 11 by inserting the Spline member 16 and more specifically ends 23 and 24 into the groove channels 6, 8, 14, 31, and 33 of the Wall Panel 11 and Partition “T” 15.

The spline member 16 provides an air tight thermal seal and a seamless insulated wall. The continuous insulated wall system eliminates the fluctuation in insulating R value, as is found in conventional construction. The use of fiberglass insulation between conventional studding causes heat loss every 16 inches, as the thermal R value of a wood or steel stud is dramatically less than fiberglass. This results in increased heating and cooling costs. Additionally, the EPS foam core 1 will always maintain the R-value properties under any conditions, whereas, the thermal properties of fiberglass fluctuate, under humid conditions and decrease with age.

As shown in FIGS. 5 & 6 multiple Wall Panels 11 can be joined using the Spline member 16, and more specifically ends 23 and 24 into groves 6 and 8 on separate Wall Panels 11.

The Corner Column 12 is used to create a right angle bend in the wall as shown in FIGS. 5 & 6. This is accomplished by inserting the Spline member 16, and more specially ends 23 and 24, into the groves 29 or 31 of the Corner Column. Then the Spline member 16, is inserted into groove channel 6 or 8 of the Wall Panel 11 to create a right angle corner.

The Partition “T” 15 is used where an adjoining partition wall is required and is joined, at the desired location, between two Wall Panels 11, using the Spline member 16 and more specifically ends 23 and 24 into the groove channels 31 or 33 of the Partition “T” 15. A continuing partition wall may now be built by joining Partition “T” 15 at end 13 to consecutive Wall Panels 11. This joint is accomplished by inserting Spline member 16 and more specifically ends 23 and 24 into the groove channel 14, 31 and 33 of the Partition “T” 15 and grove channel 6 or 8 of the Wall Panel 11. 

1. A wall finishing system, comprising: a plurality of generally rectangular, connectable panels having a rigid insulating core encapsulated with an interior finished surface on the front and back side of the insulating core.
 2. The wall finishing system according to claim 1, which provides a prefabricated Corner Column having a rigid insulating core encapsulated with an interior finished surface on all sides.
 3. The wall finishing system according to claim 2, which provides a prefabricated Partition “T” having a rigid insulating core encapsulated with an interior finished surface on all sides.
 4. The wall finishing system according to claim 3, wherein the assembly of the system is enabled by grooved channels along the vertical edge of all components connected with a high density insulating spline.
 5. The wall finishing system according to claim 4, wherein said rigid insulating core, further comprises a medium to high density Expanded Polystyrene (EPS) foam.
 6. The wall finishing system according to claim 5, wherein said spline is constructed of a denser foam material than the rigid insulating core.
 7. The wall finishing system according to claim 6, wherein said connectable panels, further comprise a plurality of metal supports, vertically oriented within the EPS foam core.
 8. The wall finishing system according to claim 7, wherein said plurality of metal supports, further provides the utility to mount heavy wall hangings, cabinets, large televisions and similar large objects
 9. The wall finishing system according to claim 8, wherein said plurality of metal supports, acts as a substitute for conventional construction methods of framing and studding.
 10. The wall finishing system according to claim 6, wherein said prefabricated Corner Column, may be used for inside and outside corner applications.
 11. The wall finishing system according to claim 10, wherein said prefabricated Corner Column, further comprises a plurality of metal supports, vertically oriented in the foam core.
 12. The wall finishing system according to claim 6, wherein said prefabricated Partition “T”, may be used to intersect any perimeter wall where an adjacent partition wall is required.
 13. The wall finishing system according to claim 12, wherein said prefabricated Partition “T”, further comprises a plurality of metal supports, vertically oriented in the foam core.
 14. The wall finishing system according to claim 6, wherein said grooved channels, provide a receiving cavity for the insulating spline, securing the assembly joints.
 15. The wall finishing system according to claim 6, wherein said connectable panels, further comprise a plurality of circular openings passing vertically through the foam core, providing electrical/plumbing chases.
 16. The wall finishing system according to claim 15, wherein said electrical/plumbing chases, may be used as a utility access for the installation of wall mounted lighting or concealing audio, video and computer wires when installing and mounting such equipment to the wall.
 17. The wall finishing system according to claim 6, wherein said high density insulating spline provides a strong assembly of panels and components without any loss of insulation R-value.
 18. A method to assemble an interior wall system, comprising the steps of: a. using a prefabricated finished foam wall panel; b. using a foam spline, and c. attaching a plurality of other finished foam wall panels and finished foam corner columns to form a perimeter around a given interior space.
 19. The method according to claim 18, in which a finished foam “T” Partition is used to form interior walls which are perpendicular to the perimeter wall.
 20. The method according to claim 19, in which a Hat Track is used to secure the upper portion of the finished foam wall panels.
 21. The method according to claim 20, in which an L bracket is used to secure the lower portion of the finished foam wall panels.
 22. The method according to claim 21, in which structural supports imbedded within the finished foam wall panel are used as a point of anchorage for pictures, paintings, cabinets, televisions and similar heavy objects
 23. The method according to claim 21, in which the internal circular wire chases within the finished foam wall panels are used to fish electrical, plumbing and auto visual utilities through the finished foam wall panels. 